U.S. patent number 10,428,802 [Application Number 15/036,050] was granted by the patent office on 2019-10-01 for heating installation arrangement.
This patent grant is currently assigned to VESTAS WIND SYSTEMS A/S. The grantee listed for this patent is VESTAS WIND SYSTEMS A/S. Invention is credited to Joe Cuoghi, Adrian Edwards, Karl Gregory, Catherine Anne McCarroll, Paul Todd.
United States Patent |
10,428,802 |
Cuoghi , et al. |
October 1, 2019 |
Heating installation arrangement
Abstract
The present invention relates to a heating installation
arrangement and a method of forming the heating installation
arrangement for a wind turbine blade. The heating installation
arrangement (100) for a wind turbine blade comprises a sleigh
(101), wherein the sleigh (101) forms a platform of the heating
installation arrangement (100), the sleigh further includes a
recess (109), wherein the recess (109) includes one or more
connection points (110, 112) for a corresponding one or more
heating apparatus.
Inventors: |
Cuoghi; Joe (Ryde,
GB), Edwards; Adrian (Gurnard, GB),
Gregory; Karl (Cowes, GB), McCarroll; Catherine
Anne (Cowes, GB), Todd; Paul (Southampton,
GB) |
Applicant: |
Name |
City |
State |
Country |
Type |
VESTAS WIND SYSTEMS A/S |
Aarhus N |
N/A |
DK |
|
|
Assignee: |
VESTAS WIND SYSTEMS A/S (Aarhus
N, DK)
|
Family
ID: |
51897042 |
Appl.
No.: |
15/036,050 |
Filed: |
November 10, 2014 |
PCT
Filed: |
November 10, 2014 |
PCT No.: |
PCT/DK2014/050372 |
371(c)(1),(2),(4) Date: |
May 11, 2016 |
PCT
Pub. No.: |
WO2015/067278 |
PCT
Pub. Date: |
May 14, 2015 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20160290322 A1 |
Oct 6, 2016 |
|
Foreign Application Priority Data
|
|
|
|
|
Nov 11, 2013 [DK] |
|
|
2013 70662 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F03D
1/0675 (20130101); F03D 13/10 (20160501); F03D
80/40 (20160501); Y02E 10/721 (20130101); Y02E
10/722 (20130101); F05B 2260/201 (20130101); Y02E
10/72 (20130101); F05B 2260/208 (20130101) |
Current International
Class: |
F03D
80/40 (20160101); F03D 1/06 (20060101); F03D
13/10 (20160101) |
Field of
Search: |
;416/91 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1771420 |
|
May 2006 |
|
CN |
|
2861580 |
|
Jan 2007 |
|
CN |
|
101111722 |
|
Jan 2008 |
|
CN |
|
201081567 |
|
Jul 2008 |
|
CN |
|
202673585 |
|
Jan 2013 |
|
CN |
|
103184984 |
|
Jul 2013 |
|
CN |
|
19528862 |
|
Feb 1997 |
|
DE |
|
19644355 |
|
Apr 1998 |
|
DE |
|
102010043434 |
|
May 2012 |
|
DE |
|
102010051293 |
|
May 2012 |
|
DE |
|
102010051296 |
|
May 2012 |
|
DE |
|
2011122533 |
|
Jun 2011 |
|
JP |
|
2011/127995 |
|
Oct 2011 |
|
WO |
|
2013/032166 |
|
Mar 2013 |
|
WO |
|
2014/166979 |
|
Oct 2014 |
|
WO |
|
Other References
International Search Report for PCT/DK2014/050372, dated Feb. 16,
2015. cited by applicant .
Danish Search Report for PA 2013 70662, dated Jun. 11, 2014. cited
by applicant .
Chinese Office Action dated Nov. 16, 2017 for Application No.
201480061432.1. cited by applicant.
|
Primary Examiner: Jellett; Matthew W
Attorney, Agent or Firm: Patterson + Sheridan, LLP
Claims
What is claimed is:
1. A heating installation arrangement for a wind turbine blade
comprising: a sleigh within the wind turbine blade, wherein the
sleigh forms a platform of the heating installation arrangement;
and wherein a portion of the sleigh forms a recess within the
sleigh, wherein the recess forms a lower portion of an air flow
channel, wherein the air flow channel comprises an air input and an
air output, wherein one or more connection points are disposed
within the recess and correspond to one or more heating apparatuses
also disposed within the recess and the air flow channel, wherein
the one or more heating apparatuses are disposed between the air
input and the air output of the air flow channel, wherein the one
or more heating apparatuses comprise one or more of a heater and a
fan.
2. The heating installation arrangement as claimed in claim 1, in
which one or more sections of said recess form a lower portion of
ducting for channeling air flow through said heating installation
arrangement.
3. The heating installation arrangement as claimed in claim 1,
further comprising: two or more ribs, wherein the two or more ribs
extend below said sleigh; and wherein the two or more ribs form
attachment points to attach said heating installation arrangement
to an internal structure of said wind turbine blade.
4. The heating installation arrangement as claimed in claim 3,
further comprising: four ribs extending below said sleigh and
spaced at substantially equal distances along the sleigh.
5. The heating installation arrangement as claimed in claim 3 in
which the two or more ribs further comprise an indentation on an
outer edge of said rib to form a moisture channel between said rib
and an internal surface of said wind turbine blade.
6. The heating installation arrangement as claimed in claim 3, in
which said ribs further comprise one or more access points to
provide access to an area below said sleigh.
7. The heating installation arrangement as claimed in claim 1,
wherein one of the one or more connection points comprises a fan
connection point; wherein one of the one or more heating
apparatuses comprises a fan; and said fan connection point in said
recess is shaped to substantially match an external profile of said
fan installed at said fan connection point.
8. The heating installation arrangement as claimed in claim 1
wherein one of the one or more connection points comprises a heater
connection point; wherein one of the one or more heating
apparatuses comprises a heater; and said heater connection point in
said recess is shaped to substantially match an external profile of
said heater installed at said heater connection point.
9. The heating installation arrangement as claimed in claim 1
further comprising: one or more upper portion sections to form
ducting for channeling air flow through said heating installation
arrangement; and wherein the one or more upper portions sections
are attached to said sleigh over said recess.
10. The heating installation arrangement as claimed in claim 1
further comprising: an electrical junction box for connecting said
heating apparatus to electrical control signals and electrical
power.
11. The heating installation arrangement as claimed in claim 1
further comprising: one or more lifting apparatus engagement
points.
12. The heating installation arrangement as claimed in claim 1 in
which said recess is a U shape; and wherein an input for air flow
into said heating installation apparatus and an output for heated
air flow out of said heating installation apparatus are located at
one end of said sleigh.
13. The heating installation arrangement as claimed in claim 1, in
which said sleigh further comprises an input and an output wherein
air flows into said heating installation arrangement via said input
and air flows out of said heating installation arrangement via said
output.
14. The heating installation arrangement as claimed in claim 13
further comprising flexible ducting at said input or said output to
decouple said heating installation arrangement from loads,
vibrations, and noise.
15. The heating installation arrangement as claimed in claim 13, in
which said input further comprises a duct to direct air flow into
said heating installation arrangement.
16. The heating installation arrangement as claimed in claim 13, in
which said output further comprises a duct to direct air flow into
said wind turbine blade.
17. A method of forming a heating installation arrangement
comprising: forming a sleigh for a wind turbine blade from a
composite material, wherein a portion of the sleigh is formed with
a recess within the sleigh, wherein the recess forms a lower
portion of an air flow channel, wherein the air flow channel
comprises an air input and an air output; and forming one or more
connection points within the recess for a corresponding one or more
heating apparatuses disposed within said recess and the air flow
channel, wherein the one or more heating apparatuses are disposed
between the air input and the air output of the air flow channel,
wherein the one or more heating apparatuses comprise one or more of
a heater and a fan.
18. The method of forming said heating installation arrangement as
claimed in claim 17 in which one or more sections of said recess
form a lower portion of ducting for channeling air flow through
said heating installation arrangement; and attaching an upper
portion for said ducting.
19. The method of forming said heating installation arrangement as
claimed in claim 17 in which said, wherein one of the one or more
connection points comprises a fan connection point; and attaching a
fan into said fan connection point in said recess.
20. The method of forming said heating installation arrangement as
claimed in claim 17, wherein one of the one or more connection
points comprises a heater connection point; and attaching a heater
into said heater connection point in said recess.
21. The method of forming said heating installation arrangement as
claimed in claim 17 further comprising: forming two or more ribs,
wherein said ribs extend below said sleigh; and said two or more
ribs form attachment points to attach said heating installation
arrangement to an internal structure of a wind turbine blade.
22. The method of forming said heating installation arrangement as
claimed in claim 21, further comprising forming an indentation on
an outer edge of said rib to form a moisture channel between said
rib and an internal surface of said wind turbine blade.
23. The method of forming said heating installation arrangement as
claimed in claim 17, further comprising forming an input and an
output.
24. The method of forming said heating installation arrangement as
claimed in claim 23, further comprising attaching flexible ducting
to said input or said output to decouple said heating installation
arrangement from loads, vibrations and noise.
25. The method of forming said heating installation arrangement as
claimed in claim 23, further comprising attaching ducting to said
input and output to direct air flow into said wind turbine blade.
Description
The present invention relates to a heating installation arrangement
and, in particular, to a hot air heating installation arrangement
for a wind turbine blade.
Wind turbines effectively harness wind energy to generate
electrical power and are becoming increasingly popular as an
alternative energy source to the traditional sources for generating
electrical power. Harnessing wind energy is considered to be a
cleaner more sustainable source for the generation of electrical
power.
In order to generate electrical power from wind energy, wind
turbines typically comprise a tower that located on a foundation
(e.g. a solid foundation or a floating foundation, and so on), a
nacelle located on the tower to house the electrical and mechanical
apparatus, such as a gearbox, a generator, drive shafts, and a
rotor with one or more turbine blades connected to the nacelle via
a hub. In basic and simplistic terms, the turbine blades are
rotated by the incident wind energy which drives a generator to
produce electrical power.
In cold climate regions, the operation of the wind turbine can be
significantly degraded by ice accretion on the wind turbine blades.
For example, ice accretion on the blades may change the aerodynamic
shape of the blades and decrease the speed of rotation of the wind
turbine resulting in significantly reduced electrical power
production. The ice accretion will also add weight to the blades
causing increased loads on the wind turbine and potential stress
failures of the blades amongst other disadvantages caused by the
buildup of ice on the wind turbine blades.
One solution to de-icing a wind turbine blade is to circulate
heated air within the blade structure. The heated air transfers
heat to the shell structure of the blade thereby heating the blade
and subsequently enabling the removal or substantial removal of the
ice accretion from the blade.
In order to circulate heated air within the blade, a heating
arrangement comprising one or more fans, one or more heating
elements and ducting is required to be located within the
blade.
However, a wind turbine blade is a confined internal structure
which presents many difficulties for installing the heating
arrangement within a wind turbine blade during the manufacture
process. Due to the confined space within a wind turbine blade it
is also difficult for technicians to be able to enter the wind
turbine blade in order to install the individual components of the
heating arrangement. The heating arrangement is expected to last
the lifetime of the wind turbine blade and a further problem is the
ability to be able to service, maintain and/or replace the
heating/fan arrangement should it require maintenance and ease of
access to perform any maintenance.
The present invention seeks to address, at least in part, one or
more of the problems and difficulties described hereinabove.
According to a first aspect of the present invention there is
provided a heating installation arrangement for a wind turbine
blade comprising: a sleigh, wherein the sleigh forms a platform of
the heating installation arrangement; and the sleigh includes a
recess, wherein the recess includes one or more connection points
for a corresponding one or more heating apparatus.
Accordingly, the present invention provides a heating installation
arrangement that comprises a sleigh, which is effectively a
platform on which the heating apparatus may be located and
positioned. The sleigh enables the heating installation arrangement
to be advantageously formed and built separate to the wind turbine
blade which significantly minimizes the production time for a wind
turbine blade with heating apparatus for, e.g. de-icing the wind
turbine blade. Heating installation arrangements may therefore be
built or formed as a stock component and installed into wind
turbine blades as a separate unit as required. The use of the
sleigh also enables a more efficient installation of the heating
apparatus into the wind turbine blade as the individual heating
apparatus does not have to be installed separately in pieces into
the, typically, small and confined space of the internal structure
of a wind turbine blade.
The sleigh includes a recess which includes connection points for
the heating apparatus enabling the heating apparatus to be more
efficiently and effectively positioned onto the sleigh.
One or more sections of the recess may form a lower portion of
ducting for channeling air flow through the heating installation
arrangement. By utilizing the recess, in one or more sections, as
the lower portion of the ducting for channeling the air flow then
the weight of the heating installation arrangement can be
advantageously reduced and provide a more efficient heating
installation arrangement.
The heating installation arrangement may further comprise two or
more ribs, wherein the ribs extend below the sleigh; and the two or
more ribs form attachment points to attach the heating installation
arrangement to an internal structure of the wind turbine blade. The
two or more ribs that extend below the sleigh may provide strength
to the heating installation arrangement and attachment points to
the internal surface of the wind turbine blade. The ribs may attach
the sleigh to the internal structure of the wind turbine blade by
glue, bolts, or any other suitable attachment means.
The heating installation arrangement may comprise four ribs
extending below the sleigh and spaced at substantially equal
distances along the sleigh. The additional ribs may provide greater
strength and stability to the heating installation arrangement and
may provide additional attachment points to the internal
surface/structure of the wind turbine blade. As will be appreciated
there may be any number of ribs disposed at any suitable position
on the sleigh.
The ribs may include an indentation or recess to act as a moisture
channel to allow free drainage of any excess moisture within the
spar. The indentation may be formed in the ribs at an outer portion
of the rib to form the moisture channel between the rib and the
internal surface of the wind turbine blade.
The ribs may include one or more access points, for example, a
hatch or opening, to enable technicians to access the area under
the sleigh between the sleigh and the internal surface/structure of
the wind turbine blade.
The connection point in the recess may be a fan connection point
and the corresponding heating apparatus may be a fan. The fan
connection point in the recess may be shaped to substantially match
an external profile of the fan to be installed at the fan
connection point. Therefore, when constructing or building the
heating installation arrangement the fan can be slotted or
positioned in a correct alignment at the location where the fan is
to be placed. This advantageously enables a more effective and
efficient construction of the heating installation arrangement.
There may be any number of fan connection points, for example, one,
two, three, four, five, and so on. The number of fans and fan
connection points depends on the size of wind turbine blade, the
expected cold climate conditions that the wind turbine blade will
be deployed and so on, in order to effectively and efficiently blow
air through the heating apparatus and through the internal blade
cavity.
The connection point in the recess may be a heater connection point
and the corresponding heating apparatus may be a heater. The heater
connection point in the recess may be shaped to substantially match
an external profile of the heater to be installed at the heater
connection point. Therefore, when constructing or building the
heating installation arrangement the heater can be slotted or
positioned in a correct alignment at the location where the heater
is to be placed. This advantageously enables a more effective and
efficient construction of the heating installation arrangement.
There may be any number of heater connection points, for example,
one, two, three, four, five, and so on. The number of heaters and
heater connection points depends on the size of wind turbine blade,
the expected cold climate conditions that the wind turbine blade
will be deployed and so on, in order to effectively and efficiently
heat the air.
The connection points, for the heating apparatus, e.g. the fans
and/or the heaters, may further include attachment points to
securely attach and fasten the heating apparatus to the connection
point. For example, the connection point may include one or more of
bolt holes to receive bolts, strap holes and/or straps, glue
receiving portions, and so on.
The connection points may include one or more washers or seals to
ensure that the connection points and/or heating apparatus are air
tight so that no air flow is lost or escapes from the connection
points.
The heating installation arrangement may further comprise one or
more upper portion sections to form ducting for channeling air flow
through the heating installation arrangement; and the upper
portions sections may be attached to the sleigh over the recess.
Therefore, the ducting for the air flow may be formed by attaching
an upper portion of ducting over the recess where the recess forms
the lower portion of the ducting. There may be any number of
sections of the upper portion of the ducting in order to form the
ducting channel for the air flow around the heating installation
arrangement.
The upper portions are dimensioned to substantially match the
recess width in the one or more sections such that the upper
portions can be attached to the sleigh to cover the recess in the
one or more sections. The upper portion of the ducting may be
straight, curved or any other shape to enable the upper portion of
the ducting to form, with the recess in the one or more sections, a
ducting channel for the air flow through the heating installation
arrangement.
The upper portion of the ducting may be securely fastened or
attached to the sleigh. The upper portion of the ducting may be
attached using, bolts, glue, straps, or any other fastening or
attachment means to securely attach the upper portion of the
ducting to the sleigh.
Washers and/or seals may be provided between the upper portion
ducting sections, between the upper portion ducting and the heating
apparatus (e.g. fans, heaters, and so on), and/or between the upper
portion of the ducting and the sleigh in order to create an air
tight seal to prevent air loss or air escaping from the heating
installation arrangement.
The heating installation arrangement may further comprise an
electrical junction box for connecting the heating apparatus to
electrical control signals and electrical power. The electrical
junction box advantageously enables the electrical devices, e.g.
heating apparatus, sensors, and so on, to be connected to power
supply lines and/or to control/data lines in effectively a "plug
and play" manner.
The electrical junction box may be located at one end of the
sleigh. Alternatively, the electrical junction box may be located
at any suitable location on or near the sleigh to provide the
electrical and control connections to the electrical devices.
The heating installation arrangement may further comprise one or
more lifting apparatus engagement points. The lifting apparatus
engagement points advantageously enable the heating installation
arrangement to be lifted and installed in the internal cavity of a
wind turbine blade. The lifting apparatus engagement points may
include one or more of eyelet bolts on the sides or top surface of
the sleigh, holes to engage lifting apparatus such as a fork lift
truck, strapping to form a sling, and so on. As will be appreciated
there may be provided any suitable lifting apparatus engagement
points to enable the heating installation arrangement to be lifted
or moved into the internal cavity of the wind turbine blade.
The recess may be a U shape; and wherein an input for air flow into
the heating installation apparatus and an output for heated air
flow out of the heating installation apparatus are located at one
end of the sleigh. By co-locating the input and output at the same
end of the sleigh advantageously aligns the holes in a spar
structure in the blade to allow the air to flow in/out of the spar
cavity from the heating apparatus which balances the loadings to
the blade structure.
The heating installation arrangement may further comprise a
flexible ducting portion at the input and/or output of the heating
installation arrangement. The flexible ducting may de-couple the
heating installation arrangement from noise, loads, vibration
transmission that may occur when the heating installation
arrangement is installed in a wind turbine blade and in
operation.
The heating installation arrangement may further comprise an antler
and/or an elbow ducting joints on the input and/or output of the
heating installation arrangement. The antler ducting and/or elbow
ducting direct the air into and receive air from internal blade
cavities. The antler/elbow ducting may pass through an internal
spar of the wind turbine blade.
According to a second aspect of the present invention there is
provided a wind turbine blade comprising a heating installation
arrangement according to one or more of the features described
hereinabove.
According to a third aspect of the present invention there is
provided a method of forming a heating installation arrangement
comprising forming a sleigh from a composite material, wherein the
sleigh is formed with a recess; and forming one or more connection
points for a corresponding one or more heating apparatus in the
recess.
By constructing or forming the sleigh from the composite material
then the sleigh will be sufficiently strong so as to support the
heating apparatus and also will not be prone to, or induce,
lightning strikes to the blade as the composite material is
non-metallic.
The sleigh may be formed by a moulding process in which the
composite material may be laminated on a mould and then infused
with a resin which may then be cured (e.g. by heating in an oven).
Alternatively or additionally, the sleigh may be spray built using
chopped strand matt.
It may be advantageous to form the sleigh as a single unit due to
the strength and stability that a single moulded sleigh could
provide, and it reduces the need for additional manufacturing steps
relating to joining separate sleigh sections together and any
possibly weaknesses such joins may introduce.
However, as will be appreciated, the sleigh may alternatively be
formed from two or more sleigh sections that can be joined together
to make a complete sleigh, in other words, in a modular design
concept.
One or more sections of the recess may form a lower portion of
ducting for channeling air flow through the heating installation
arrangement; and attaching an upper portion for the ducting.
The connection point may be a fan connection point; wherein the
heating apparatus may be a fan and attaching the fan into the fan
connection point in the recess.
The connection point may be a heater connection point; wherein the
heating apparatus may be a heater and attaching the heater into the
heater connection point in the recess.
The method of forming the heating installation apparatus may
further comprise forming two or more ribs, wherein the ribs extend
below the sleigh; and the two or more ribs form attachment points
to attach the heating installation arrangement to an internal
structure of a wind turbine blade.
The method of forming the heating installation apparatus may
further comprise forming a moisture channel in the two or more ribs
to enable drainage of any excess moisture in the wind turbine
blade.
The method of forming the heating installation apparatus may
further comprise forming one or more access points in the two or
more ribs.
The method of forming the heating installation apparatus may
further comprise attaching an electrical junction box the sleigh.
The electrical junction box may be connected to one or more
electrical devices, e.g. heating apparatus, sensors, and so on. The
electrical junction box may provide power, control and/or data
lines to the electrical devices.
The method of forming the heating installation apparatus may
further comprise attaching one or more sections of an upper portion
of ducting to the sleigh over the recess, which forms the lower
portion of the ducting to provide a ducting channel for the airflow
through the heating installation arrangement.
The method of forming the heating installation apparatus may
further comprise forming the sleigh in one or more sections.
The method of forming said heating installation arrangement may
further comprise forming an indentation on an outer edge of said
rib to form a moisture channel between said rib and an internal
surface of said wind turbine blade.
The method of forming said heating installation arrangement may
further comprise forming an input and an output.
The method of forming said heating installation arrangement may
further comprise attaching flexible ducting to said input and/or
said output to decouple said heating installation arrangement from
loads, vibrations and/or noise.
The method of forming said heating installation arrangement may
further comprise attaching elbow ducting and/or antler ducting to
said input and/or output. The elbow and/or antler may be formed of
flexible material or non-flexiblematerial or a combination
thereof.
Embodiments of the present invention will now be described, by way
of example only, and with reference to the accompanying figures, in
which:
FIG. 1a shows a drawing of a sleigh according to many of the
embodiments of the present invention.
FIG. 1b shows a drawing of one end of the heating installation
arrangement according to many of the embodiments of the present
invention.
FIG. 2 shows a drawing of the heating installation arrangement
according to many of the embodiments of the present invention.
FIG. 3 shows a drawing of an input and output arrangement according
to many of the embodiments of the present invention.
FIG. 1 shows a schematic drawing of a lower portion of a heating
installation arrangement 100 according to many of the embodiments
of the present invention. The lower portion of the heating
installation arrangement 100 comprises a sleigh 101. The sleigh 101
is effectively a platform on which heating apparatus (e.g. heaters,
fans, cowls, ducting, and so on) may be integrated and/or attached,
as will be described in more detail heareinbelow.
The sleigh 101 may be formed as a single unit (as shown in FIG. 1)
where the sleigh may be formed from a single piece of composite
material, such as E glass Glass Reinforced Plastic (GRP) and/or
Prime 20 epoxy infusion resin and/or other resins such as
polyester, vinylester, and so on.
By constructing or forming the sleigh 101 from the composite
material then the sleigh 101 will be sufficiently strong so as to
support the heating apparatus and also will not be prone to, or
induce, lightning strikes to the blade as the composite material is
non-metallic.
The sleigh 101 may be formed by a moulding process in which the
composite material may be laminated on a mould and then infused
with a resin which may then be cured (e.g. by heating in an oven).
Alternatively or additionally, the sleigh may be spray built using
chopped strand matt.
It may be advantageous to form the sleigh as a single unit as shown
in FIG. 1 due to the strength and stability that a single moulded
sleigh could provide, and it reduces the need for additional
manufacturing steps relating to joining separate sleigh sections
together and any possibly weaknesses such joins may introduce.
However, as will be appreciated, the sleigh may alternatively be
formed from two or more sleigh sections that can be joined together
to make a complete sleigh 101, in other words, in a modular design
concept.
At each end of the sleigh 101, there may be a rib or fin 102, 103
extending below the bottom of the sleigh 101. The ribs 102, 103 may
be integrated with the sleigh 101 or may be formed separate to the
sleigh 101 and attached thereto during the manufacture of the
sleigh 101.
The ribs 102, 103 may be connected to or attached to the internal
blade structure of the wind turbine blade once the heating
installation arrangement is installed into the wind turbine blade,
for example, by gluing and/or bolting the ribs to the internal
structure of the blade. The internal structure of the blade may
also include guides or spars that are to be connected to the ribs.
The ribs 102, 103 may also provide additional support and strength
to the heating installation arrangement.
The sleigh 101 may further include one or more additional ribs 104
that extend below the sleigh 101 at predetermined positions. The
one or more additional ribs 104 may provide additional support and
strength to the sleigh 101 and may also provide further attachment
points to attach the sleigh to the internal structure of the blade.
In FIG. 1 there is shown 2 additional ribs 104 at equal distances
between the two end ribs 102, 103 however, as will be appreciated,
there may be any number of ribs 104 extending below the sleigh to
provide stability and attachment points for the sleigh 101.
The ribs may be formed with a recess or indentation at the lower
point of the rib to provide a moisture channel to enable free
drainage of any excess moisture within the blade. The indentation
may be located on an outer edge of the rib so that the moisture
channel is formed between the rib and an internal surface of the
wind turbine blade structure.
Alternatively, the sleigh 101 may not include the ribs 102, 103,
and/or the additional ribs 104 such that the sleigh may be attached
directly to the internal structure of the wind turbine blade.
Alternatively, or additionally, the ribs may include one or more
access panels or routes to allow technicians and personnel access
to the underside of the heating installation arrangement.
With reference to FIG. 1b, which shows a view of one end 103 of the
sleigh 101, the end rib 103 may include openings 105 to enable a
lifting means, such as a fork lift truck, a crane, or any other
suitable means, to engage with the sleigh 101 to maneuver the
sleigh 101 into the correct position within the internal structure
of the blade. Alternatively, or additionally, the end rib 103 may
include one or more couplings to couple to the lifting means.
Referring to FIG. 1a, the top of the sleigh 101 may additionally or
alternatively include one or more attachment means 106, e.g.
eyebolts, to operatively connect to a lifting apparatus to enable
the sleigh 101 and heating installation arrangement 100 to be
positioned within the internal structure of the blade. In the
example shown in FIG. 1a, there are four eyebolts located in the
corners of the top of the sleigh, however as will be appreciated,
there may be any number of attachment means which may be located at
suitable positions, e.g. the end of the sleigh, top of the sleigh,
side of the sleigh, and/or bottom of the sleigh.
The heating installation arrangement may alternatively or
additionally include straps to form a sling around the heating
installation arrangement to aid the lifting and moving of the
heating installation arrangement.
Returning to FIG. 1b, the heating apparatus to be integrated with
or located in/on the sleigh to form the heating installation
arrangement 100 may include one or more electrical devices such as
heaters, fans, and so on. Therefore, one of the end ribs 103 of the
sleigh 101 may further include an electrical connector 107, e.g. an
electrical junction box. The electrical connector 107 can provide
connections for electrical cabling/wiring, guides for the
electrical cabling/wiring to pass through unto the sleigh, and/or
the electrical connector may provide a so-called "plug and play"
electrical connection to the electrical devices of the heating
installation apparatus.
The electrical connector 107 may include one or more of
controllers, processors, connections, memory, or any other
electrical equipment necessary to power and control the electrical
devices installed in or on the sleigh.
Referring to FIG. 1a, the central area of the sleigh 108 may
include openings, cable guides and/or connectors for the electrical
cabling/wiring to the various electrical components/devices of the
heating installation arrangement. This advantageously enables the
components (e.g. fans, heaters, etc.) to be conveniently and
efficiently connected to power supplies and cables communicating
with the components to provide control data and instructions.
The sleigh 101 is formed with a recess 109 for the installation of
the components of the heating apparatus. For example, the recess
109 may be formed to enable individual components of the heating
apparatus, e.g. heaters, fans, etc., to fit within the recess 109.
One or more sections of the recess 109 may also form the lower
portion of ducting through which the air can flow for the hot air
de-icing or enable separate ducting to fit within the recess
109.
The recess 109 formed in the sleigh 101 is substantially a "U"
shape in the embodiment shown in FIG. 1a. However, as will be
appreciated, the recess 109 may form any suitable shape for the
heating installation arrangement, for example, an "S" shape, "T"
shape, "Y" shape, and so on. The recess 109 in this embodiment is a
"U" shape as this enables the heating installation arrangement to
be compact and simpler to install in the wind turbine blades.
Within the recess 109, there may be formed one or more fan
connection points such that a fan can be located within the recess
in order to blow the air through the heating apparatus. In FIG. 1a,
there are shown three fan connection points 110 within which fans
may be located or installed. However, as will be appreciated, the
heating installation arrangement may include one or more fans in
order to ensure a sufficient air flow through the heating apparatus
and into the blade internal cavity.
The fan connection points 110 are formed to enable the fans to be
installed and slotted into position. Therefore the shape of the
recess at the fan connection points 110 is such that it matches the
external shape of the fan that is to be located within the recess
of the sleigh at the corresponding fan connection point 110. Either
side of the recess at the fan connection points there may be
connectors or openings 111 for bolts, or other coupling means, e.g.
straps, to allow the fan to be securely attached to the sleigh at
the fan connection point 110.
At either end of each fan there may be installed one or more seals,
washers, or any other suitable means to ensure that air does not
flow around or escape from the location of the fans.
Within the recess 109 there may also be formed one or more heater
connection points 112 at which heaters can be located within the
recess in the sleigh. In the embodiment shown in FIG. 1a, there are
two heater connection points 112 but as will be appreciated there
may be any number of heaters in the heating installation
arrangement to ensure that the air flowing through the heating
apparatus can be sufficiently heated to enable an effective and
substantial de-icing of the wind turbine blade.
The heater connection points 112 are formed to enable the heaters
to be installed, e.g. slotted into position, and therefore the
shape of the recess at the corresponding heater connection points
112 is such that it matches the external shape of the heater that
is to be located or positioned within the recess of the sleigh.
Either side of the recess at the heater connection points there may
be connectors 113, e.g. openings for bolts, or other
coupling/attachment means, e.g. straps, to allow the heater to be
securely attached to the sleigh at the heater connection point
112.
At either end of each heater there may be installed one or more
seals, washers, or any other suitable means to ensure that air does
not flow around or escape from the location of the heaters.
The recess 109 formed in the sleigh 101 that lies between, or
connecting, the heaters and fans in the heating apparatus may be
used for ducting to channel the air flow through the heating
installation arrangement. Preferably, the recess 109 in the
sections between the heaters, fans, input and output of the heating
installation arrangement forms the lower portion of the ducting
through which the air will flow. By utilizing the recess channel as
the lower portion of the ducting the weight of the heating
installation apparatus can advantageously be reduced as no
additional separate ducting is required for the lower portion of
the air flow channel.
Air may inflow to the heating installation arrangement at an input
114 and the heated air may outflow from the heating installation
arrangement at an output 115.
FIG. 2, shows a schematic of the heating installation arrangement
201 with the upper portion of the ducting 202 attached, three fans
205 installed and two heaters 206 installed.
The upper portion of the ducting 202 may be attached to the sleigh
203 over the recess such that when the upper portion of the ducting
is attached to the sleigh 203 then the combination of the lower
portion formed by the recess in the sleigh 203 with the attached
upper portion of the ducting 202 forms the complete ducting channel
through which the air can flow.
The upper portion of the ducting is preferably formed in sections
and attached to the sleigh 203 over the recess. There may be one
section that connects the input 204 to the first fan 205a, one
section between the first fan 205a and the second fan 205b, one
section between the second fan 205b and the third fan 205c, one
section between the last fan 205c and the first heater 206a forming
the curved end of the "U" shape, one section between the first
heater 206a and the last heater 206b, and one section between the
last heater 206b and the output 207 of the heating installation
arrangement.
However, as will be appreciated, there may be any number of
sections of the upper portion of the ducting that is attached to
the sleigh 203 in order to form the complete ducting channels in
combination with the lower portion formed by the recess in the
sleigh 203. For example, the section forming the curved end of the
upper portion of the ducting may be formed in two or more
sections.
The sleigh may include one or more connection points, e.g. holes
for bolts, area for glue, or any other attachment or coupling
means, e.g. straps, so that the upper portion of the ducting along
with the heaters and fans can be securely fastened and attached to
the sleigh. In the example shown in FIG. 2, the heaters 206 and
fans 205 are securely fastened to the sleigh 203 via straps 208 and
bolts. The upper portion of the ducting in this example is securely
fastened to the sleigh using bolts.
Between the upper portion of the ducting and the sleigh there may
be included one or more seals to form a substantially air tight
seal between the upper portion of the ducting and the recess in the
sleigh forming the lower portion of the ducting channel for the air
flow to ensure that no air leaks or escapes from the ducting
channel. Also, between each of the upper portion of the ducting
sections there may also be implemented one or more seals to form a
substantially air tight seal between the sections of the upper
portion of the ducting to ensure that no air leaks or escapes from
the ducting channel.
Alternatively, the recess may be formed such that the shape of the
recess matches the external shape of ducting that could be
positioned in the recess. In this arrangement the ducting will slot
into the recess to form the ducting channels through which the air
can flow.
As described hereinabove, in the embodiments the heating
installation arrangement is a "U" shape and therefore the input air
flow and output air flow of the heating installation arrangement
are both located or positioned at the same end of the sleigh 203.
As will be appreciated, the shape of the heating installation
arrangement may be any suitable shape, e.g. an "S" shape, an "L"
shape, "T" shape, "Y" shape, and so on, where the input 204 and
output 207 of the heating installation arrangement may be located
on different sides and or different ends of the sleigh 203.
The "U" shape is particularly advantageous as it provides a compact
and efficient solution to the problems and difficulties associated
with installing the heating apparatus in a wind turbine blade,
which has a confined space. Furthermore, with the "U" shape the
input and output are co-located at the same edge or side of the
sleigh which advantageously aligns the holes in a spar structure in
the blade to allow the air to flow in/out of the spar cavity from
the heating apparatus which balances the loadings to the blade
structure.
An example of the input and output channel arrangement 301 is shown
in FIG. 3. On the input side 302 there is provided an antler duct
303 the end 304 of which passes through the spar structure within
the blade cavity to enable air flow into the heating installation
arrangement from the leading edge cavity within the blade
structure. On the output side 305 there is provided an elbow duct
306 the end 307 of which passes through the spar structure within
the blade cavity to enable heated air to flow from the heating
installation arrangement to the trailing edge cavity within the
blade structure. As will be appreciated, the structure and
arrangement of the input and/or output channels may be any suitable
arrangement to direct the air flow from the heating installation
arrangement to one or more internal cavities in the blade structure
and also to receive air flow from one or more internal cavities in
the blade structure to the heating installation arrangement. The
output of the heating installation arrangement may alternatively or
additionally channel heated air into the leading edge cavity and
the input of the heating installation arrangement may alternatively
or additionally receive air flow from the trailing edge cavity of
the blade structure.
On the input and/or output of the heating installation arrangement
there may be provided one or more flexible ducting portions. The
flexible ducting may de-couple the heating installation arrangement
from noise, loads, and/or vibration transmission that may occur
when the heating installation arrangement is installed in a wind
turbine blade and in operation.
Returning to FIG. 2, one end 209 of the sleigh 203 may include an
electronic junction box 210 and one or more connection points 211
to which lifting gear or apparatus, e.g. a fork lift truck, may
engage to lift the heating installation arrangement 201. The top of
the sleigh 203 may alternatively or additionally include one or
more attachment points 212, e.g. eye bolts, to enable lifting
apparatus, e.g. a crane, to engage or attach to the sleigh 203 to
enable the heating installation arrangement to be lifted or winched
into the internal blade cavity.
Accordingly, the heating installation arrangement can be
effectively positioned within the blade internal cavity via the
lifting apparatus.
The ribs 213 extending below the sleigh 203 provide strength and
support to the heating installation arrangement and/or provide
connection points to securely attach the heating installation
arrangement to the internal structure of the wind turbine
blade.
One end of the sleigh may also include one or more access points to
enable technicians to access the heating installation arrangement
and the underside of the heating installation arrangement. The ribs
of the heating installation arrangement may also be provided with
access points for technicians to be able to access one or more
areas and structures of the heating installation arrangement.
The heating installation arrangement shown in FIG. 2, includes
three fans 205 and two heaters 206 however, as will be appreciated
there may be any number of fans and/or heaters in the heating
installation arrangement as required to sufficiently heat the air
flow and to provide a sufficient flow of heated air into the size
of blade that is to be de-iced.
The dimensions of the heating installation arrangement will be
appropriate for the size of blade and the size of the internal
blade cavity in which the heating apparatus is to be installed. For
example, the dimensions of the sleigh may be 5 meters.times.2
meters.times.0.5 meters to be installed in a blade internal cavity
having a root diameter dimension of 2.4 meters. However, as will be
appreciated, different blades for different types of wind turbines
may have different dimensions and therefore, the heating
installation arrangement can be of any suitable dimensions in order
to fit inside the blade that the heating apparatus will be
installed within.
As described hereinabove, the sleigh and ribs may be formed from a
composite material which is both lightweight and does not induce
lightning strikes to the wind turbine or wind turbine blade. The
sleigh and ribs may be formed as a single piece or may be formed in
sections which are joined together, e.g. using glue, bolts, or
other fastening means. The sleigh and ribs may be formed using a
universal mould or a mould that is designed for the specific size
and shape of each wind turbine blade cavity that the heating
installation arrangement may be installed. The mould may be infused
with the composite material in resin form and cured, e.g. in an
oven, to become a solid structure. The fans, heaters and upper
portion of the ducting may then be securely attached or fastened to
the sleigh in order to form the complete heating installation
arrangement which may then be installed within the internal blade
cavity.
The embodiments of the present invention describe a heating
installation apparatus that has many advantages. The heating
apparatus can be manufactured separately to the blade and then
lifted into the blade internal cavity to be attached and installed.
This means that the difficulty in installing the heating apparatus
is advantageously reduced as the separate parts of the heating
apparatus do not need to be installed separately by technicians in
the confined space of the blade internal cavity.
By forming and manufacturing the heating installation apparatus
separately or remotely to the blade production then the production
time of the blade is also reduced or minimised. This is because the
heating installation arrangement is built separately to the blade
production and is installed into the blade once the heating
installation apparatus and the blade have been built. Therefore,
any number of heating installation arrangements can be formed and
built so that they are ready to be installed in any number of
blades as and when required.
Furthermore, the ability to maintain and repair the heating
apparatus when installed using the described heating installation
arrangement is more effective and efficient.
While embodiments of the invention have been shown and described,
it will be understood that such embodiments are described by way of
example only. Numerous variations, changes and substitutions will
occur to those skilled in the art without departing from the scope
of the present invention as defined by the appended claims.
Accordingly, it is intended that the following claims cover all
such variations or equivalents as fall within the spirit and the
scope of the invention.
* * * * *